With the ignition switched off and the parking brake set, disconnect the negative battery cable and cover the terminal with proper insulation.
IMPORTANT: Failure to disconnect the battery for a minimum of 2 hours may cause the Check Engine Light to illuminate upon completion of the installation or subsequent operation. DO NOT SKIP THIS STEP!
Squeeze the sides of the SAI (Secondary Air Inlet) tube head to disconnect SAI connection.
Remove the vacuum line by carefully using a small pointed tool to break the initial adhesion. Simultaneously pull on the vacuum line to remove.
Using large pliers, squeeze the spring clamp that holds the intake tube onto the air box then slide the spring away from the groove.
Pull-on the intake tube to separate it from the upper airbox.
Loosen and remove all 8 T-25 Torx fasteners that hold the upper airbox to the lower. Remove the upper airbox.
Use a 7mm or 10mm (model year dependent) socket or wrench to loosen the clamp that holds the intake tube to the turbo inlet manifold. Carefully pull (some force required) on the base of the intake tube to remove from the turbo inlet manifold.
Use Hands to gently pull flexible coolant hose from a fixture on the grill intake plenum. Using a tool could puncture/ compromise the coolant line. Be careful to not tug on the attachment point on the radiator side, it is fragile.
Use T-25 Torx driver bit to loosen the two fasteners that are holding the grill intake plenum cover on. In the middle of the grill intake cover, locate the plastic holding tab. Pull back to release the cover.
The remaining plastic piece is held by interference/snap-fit. Start on the passenger side of the vehicle, and undo each snap-fit, until you reach the tab on the driver's side. Press in this tab to release the part.
Using both hands and gripping the box from the bottom, tug upwards to release the box from each of the 3 rubber grommets that the prongs fit into.
To create clearance for the air box, the power cable running from the positive battery terminal to the starter, will be separated from the primary positive battery cable and routed underneath the battery tray. Carefully cut or release the zip tie that holds the two positive cable leads together. Use a panel removal tool to remove the (2) plastic rivets holding the cable to the battery tray.
With the starter cable now separated, route it under the battery tray. If the positive battery terminal was disconnected, slide the cable terminal back onto the battery post.
Run the provided Cable Tie (V) through the hole where the plastic rivet was and around the starter power cable. Tighten until the cable is secure. Trim excess cable tie length.
Prepare the Air Intake Box (A) for installation. Insert three 0.5” ID Grommets (F) into the open holes on the bottom.
Optional: insert Silicone Airbox Plug (G).
Install the silicone Tube Seal (H) onto the Air Intake Box (A). Insert the larger diameter side of the Air Intake Tube (B) through the outside of the tube seal towards the inside of the airbox. Stop before the 1/8” NPT bump is at the tube seal.
Install the Inlet Seal (D) by correctly orienting the part with the box and pushing the groove of the silicone part all the way around the opening of the airbox.
With the SAI tube cleared out of the way, bring the airbox above the location where it should be installed and slowly lower while aligning the 3 mount prongs with the rubber Grommets (F) that were already installed on the airbox. This step may be made considerably easier by applying soapy water to the prongs and grommets. Be sure that the grommets remain on the box and don’t get pushed through (it may be helpful to use a second pair of hands to hold them in place while installing).
Slide the larger side of the Step Coupler (E) over the Air Intake Tube (B). Slide Hose Clamp #52 (S) followed by Hose Clamp #44 (R) over the step coupler. Tighten Hose Clamp #52 to hold the coupler to the intake tube. Push the smaller end of the coupler over the turbo inlet manifold, and tighten Hose Clamp #44.
Insert the chamfered end of the aluminum SAI Adapter (I) into the larger diameter end of the SAI Coupler (C). Slide Hose Clamp #20 (P) over this end and tighten. From the outside of the airbox, insert the smaller diameter end of the SAI Coupler through the hole and press until the ring on the SAI Coupler is on the inside of the box.
Place Hose Clamp #8 (O) over the end of the SAI Coupler (C) from inside the airbox and insert the SAI Breather Filter (L). Tighten the hose clamp.
Connect the SAI hose to the aluminum SAI Adapter (I) by aligning the head of the SAI hose and pushing it over the adaptor until it is locked in place. You may need to pull the SAI hose to give more slack for easier coupling.
Thread the Nylon Elbow (N), into the 1/4” NPT threaded fitting. End the elbow’s rotation after it is finger-tight and facing towards the front/center of the vehicle. Slide the vacuum line over the pronged side of the elbow.
Install the grill inlet piece in reverse order of how it was taken apart (refer to Steps 9-10). Be sure that the Inlet Seal (D) is around the mouth of the grill inlet. Also, be sure that all snap fits are correctly engaged...go to Step 23b.
...continued from Step 23a.
Place Hose Clamp #56 (Q) over the Air Filter (J) flange. Install the air filter onto the Air Intake Tube (B) in the airbox. Tighten the clamp.
Press the Lid Groove Seal (K) into the groove of the Intake Box (A). Place the Clear Lid (M) into position on the intake box and fasten with the Counter Sunk Washers (U) and Flat Head Screws (T).
Attach battery terminals to battery posts and tighten the terminals.
Inspect your installation, make sure the kit is properly positioned and all fasteners are secure. Keep all stock parts in case you would ever need to reinstall the stock intake assembly. Affix the ID label near the intake kit. The installation is now complete.
